Flexible film plate-mat bag

ABSTRACT

A method for forming a plate-mat bag using a form, fill, and seal machine and the resultant bag. The film used to form the bag is oriented so that the product side layer is not a critical barrier layer. The top most portion of the bag is unsealed forming a tab. Below the top most portion, a peelable upper seal is utilized so that a consumer can destroy the upper seal using the tab and tear open the bag along slits made in the product side layer. This results in an easy open package which when opened can serve as a plate.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to an easy to open package, designed in aplate-mat bag configuration, and a method for making same. When thepackage of the present invention is opened it forms a plate which theconsumer can set on a surface and consume the packaged contents. Severalfeatures of one end of the package provide for easy opening of thepackage by a consumer.

2. Description of Related Art

Snack foods and other items are often packaged in bags formed from thin,flexible packaging films. These thin films are formed primarily ofplastics, such as polypropylene and polyethylene, but can also containmetalized films, foil, paper, or oriented films. These packaging filmscan have numerous layers directed to achieving specific needs, but aregenerally formed at least in part by extrusion of a plastic layer,co-extrusion of multiple layers simultaneously, extrusion coating ofanother material (such as paper), and the lamination of two layerstogether via either extrusion lamination or adhesive lamination. In thediscussions below, both extrusion lamination and adhesive laminationprocesses are discussed in more detail, but it is noted that anydesignated layer that is fed into these two processes can already be amulti-layer film formed by any of the above processes.

An exemplary film 100 for packaging of food products is seen in FIG. 1.The outermost layer 102 is an OPP layer, short for orientedpolypropylene, while the innermost layer 106 is a metalized OPP or otherbarrier material. An oriented polymer material has been speciallytreated so that the long polymeric molecules tend to align in a givendirection, causing the material to preferentially tear in thatdirection. Sandwiched between the two OPP layers 102, 106 is an adhesivesuch as polyethylene 104 or other adhesive. Printing for the package isdone on the inside of the outer layer and becomes sandwiched between themiddle and outer layers. The innermost, metallic layer 106 can itself bea layered laminate and contains a sealant layer 108 on what will be theinside, or product side, of the package. This sealant layer 108 istypically formed of a ter-polymer, composed of ethylene, propylene, andbutylenes, along with the metallic layers, and provides a barrier toretain taste and freshness of the product contained therein. Othermaterials used in packaging are polyester, paper, polyolefin extrusions,adhesive laminates, and other such materials, or a layered combinationof the above.

Once the material is formed and cut into desired widths, it can beloaded into a vertical form, fill, and seal machine to be used inpackaging the many products that are packaged using this method. FIG. 2shows an exemplary vertical form, fill, and seal machine that can beused to package snack foods, such as chips. This drawing is simplified,and does not show the cabinet and support structures that typicallysurround such a machine, but it demonstrates the working of the machinewell. Packaging film 210 is taken from a roll 212 of film and passedthrough tensioners 214 that keep it taut. The film then passes over aformer 216 which directs the film as it forms a vertical tube around aproduct delivery cylinder 218. This product delivery cylinder 218normally has either a round or a somewhat oval cross-section. As thetube of packaging material is pulled downward by drive belts 220, theedges of the film are sealed along its length by a vertical sealer 222,forming a back seal 224. The machine then applies a pair of heat-sealingjaws 226 and accompanying jaw face 233 against the tube to form atransverse seal 228. Different shapes of jaw faces 233 result indifferent shaped seals. The transverse seal 228 acts as the top seal onthe bag 230 below the sealing jaws 226 and the bottom seal on the bag232 being filled and formed above the jaws 226. After the transverseseal 228 has been formed, a cut is made across the sealed area toseparate the finished bag 230 below the seal 228 from the partiallycompleted bag 232 above the seal. The film tube is then pushed downwardto draw out another package length. Before the sealing jaws form eachtransverse seal, the product to be packaged is dropped through theproduct delivery cylinder 218 and is held within the tube above thetransverse seal 228.

The form, fill, and seal machines are quite expensive, in the range of$250,000 each, but pay for themselves easily when compared to the costof pre-formed bags and the machinery to fill them. However, in order tomaximize the productivity of the form, fill, and seal machines, it iscommon for the product delivery tube 218 and former 216 to be made as aunit that is easily interchangeable, so that different size packages canbe made by the same machine. The length of the transverse seal can alsobe changed, by exchanging the sealing jaws 226, or in some cases, merelyby exchanging their facings (the portion of the sealing jaws whichactually makes contact with the packaging film). By changing theseelements, as well as the width of film roll feeding into the machine andthe programming of the machine, one form, fill, and seal machine canhandle a number of different products in different size packages,limited primarily by the width of film the machine will handle, themaximum length of bag the machine is designed to handle, and theavailable former/delivery tube assemblies.

Although there is no one perfect package for all uses, there are anumber of desirable features that manufacturers strive for in packagesmade on a vertical form, fill, and seal machine. One such feature is theability to easily open the package. Consumers now must grip and open thepackage, usually with a thumb and one or several fingers on both hands.The thumb and fingers must pinch and tear with sufficient force to breakthe seal. This can become more difficult as a consumer gets older. Forexample, some consumers have arthritis or have lost strength in theirhands. Grasping the sides of a flexible bag and opening it as previouslydescribed may be a difficult task for them. Therefore, it is desirableto have a bag that is easier to open by hand than is available from theprior art. There have been some attempts at this to include an easy openpackage containing, for example a tear notch and perforations that allowfor easier opening. However, even these traditional pillow containershave a downside in that when opened the package falls on its side andconsequently must be balanced to keep product from spilling. Thus, it isdesirable to have a package that does not need to be balanced for fearof spillage. New stand-up packages have been developed that ease thebalancing problem such as the package disclosed by commonly owned U.S.Pat. No. 6,722,106 to Bartel et al. However, these vertical stand-uppackages still only offer a small cross-sectional area from whichproduct can be retrieved. Many consumers prefer the ease of eatingsnacks from a plate or a bowl that offers a relatively large surfacearea for product retrieval rather than a package wherein a consumer'shand must be inserted into the package to retrieve a food product. Thus,it is also desirable to have a package that offers maximum surface areafrom which product can be retrieved. Consequently, it is desirable tohave an easy to open package that upon opening functions as a“plate-mat” which holds food product. The word “plate-mat” comes fromcombining plate and placemat, and means a container that is generallyhorizontal when opened such that it can be eaten from like a plate. Afeature of the container can also be used as a placemat once thecontainer is open. Finally, because of the speed and productivityachieved on a vertical form, fill, and seal machine, it is desirablethat any such package alteration be capable of being produced on such amachine.

SUMMARY OF THE INVENTION

A flexible easy to open package that also serves as a plate for storingand eating food and method for making same is provided. The packagecomprises two seals: a lower seal and an upper peelable seal. The upperseal has geometry so that as the seal is pulled downward, the force getsdistributed downward and outward. There is a portion of unsealed filmabove the upper seal which forms a tab. This allows a consumer to easilygrip the tab and pull downward, breaking the upper seal and opening thepackage. The inner layer of the package has score lines. Consequently,as the consumer breaks the upper seal, the package continues to tearalong the direction of the score lines. Once opened, the packageresembles a plate. Further, the torn top portion of the package can beused as a place-mat upon which cups or drinks or other items may beplaced.

The package is capable of being produced on a vertical, form, fill, andseal machine with only minor alterations. First, a film is obtainedwherein the first layer, or product side, of a film web comprises scorelines. The film is oriented so that it preferentially tears in thedirection of the score lines. The resulting film is fed to a vertical,form, fill and seal machine. The package is then formed into a tube,sealed at the bottom, filled with product, and then sealed at the topwith a peelable seal. The peelable seal is made peelable by adjustingsuch factors as time, temperature, pressure, as well as the geometry ofthe seal. Further, the peelable seal has a force distributingconfiguration which directs the force downward and outward along thepackage as the consumer opens the package.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbe best understood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 depicts a cross-section of an exemplary prior art packaging film.

FIG. 2 depicts a vertical form, fill, and seal machine that is known inthe prior art.

FIG. 3 depicts a perspective view of one embodiment of a package in theinstant invention.

FIG. 4 depicts a top planar view of one embodiment of the instantinvention wherein the top has been torn to reveal a plate of product.

FIG. 5 depicts a cross-section of a packaging film of one embodiment ofthe current invention.

FIG. 6 depicts the formation of the packaging film of FIG. 5 accordingto one embodiment.

FIG. 7 depicts a top planar view of the packaging film which is used toproduce the plate-mat package.

FIG. 8 depicts a perspective view of one half of the seal jaws and jawface used in one embodiment of the current invention.

DETAILED DESCRIPTION

Several embodiments of Applicants' invention will now be described withreference to the drawings. Unless otherwise noted, like elements will beidentified by identical numbers throughout all figures.

FIG. 3 depicts a perspective view of one embodiment of a package underthe instant invention. The package preferably comprises a flexible filmweb and more preferably comprises an oriented film such as an orientedpolymer material. As used herein a flexible film web is a web comprisingat least two flexible layers. An oriented polymer material is a polymermaterial which has been specially treated so that the long polymericmolecules tend to align in a given direction, causing the material topreferentially tear in that direction. The package is preferablyoriented so that it preferentially tears along its vertical axis. Thepackage in this embodiment further comprises a front panel 306comprising a left and right side, a back panel 307 contiguous with thefront panel, a bottom seal 301, an upper seal 302, at least two scorelines 303 vertically oriented along the right and left side of the frontpanel and running parallel from the upper seal to the bottom seal, tearslots 304, and a tear tab 305. The bottom seal 301 is formed by heatseal jaws similar to those depicted in FIG. 2. It should be noted thatthe top portion of the bag comprises a tear tab 305 which is anextension of the package film above the upper seal 302. Thus, the topmost portion of the bag between the tear slots 304 and above the upperseal 302 is not sealed. Because the front panel 306 is not sealed withthe back panel 307 in this area, a tear tab 305 is formed. Two or moretear slots 304 can be made by any means known in the art such as a knifeand anvil. It can be appreciated that because the tear tab 305 is notsealed a consumer can grip the tear tab with ease. Thus, a consumer cangrab the tear tab 305 on the top panel 306 of the package and easilymanipulate it as it is not sealed to the back face 307 of the package.In some larger packages, the tear tab 305 will be large enough for aconsumer to grab with an entire hand. Even in smaller packages, the teartab 305 will be large for the consumer to securely grab the tab with aplurality of fingers. After grabbing the tear tab 305, a consumer canexert a downward force. The downward force will follow the path of leastresistance in the direction provided by the tear slots 304.

Upon pulling the tear tab 305, the consumer's force will first bedirected upon the tip 308 of the upper seal 302. As will be discussed inmore detail below, the upper seal 302 is a peelable seal which istypically easier to destroy. It can be seen that one benefit of theupper seal 302 is that the seal comes to a tip 308. As depicted, theupper seal 302 is a chevron seal. The use of a chevron seal is shownonly as a preferred embodiment and should not be deemed limiting. Otherpossible examples include a semicircle or any other shape that exhibitsa force distributing configuration. As used herein a force distributingconfiguration is a configuration that concentrates the force at a forceconcentrating area such as a narrow tip and then distributes the forcesdownward and outward. Other shapes that do not concentrate the initialforce at a narrow tip can be used, but such shapes result in increasedforce being necessary to initiate the tear and open the package. Theseal has a seal area of a defined width and length. In a preferredembodiment the seal has a tip 308, defined herein as a forceconcentrating area. In a preferred embodiment the seal area at the tipis narrower than the width of the seal along the rest of the seal. Sucha configuration allows for even greater concentration of force resultingin easier tear initiation. A chevron seal is used as the upper seal 302in part because of its defined tip 308, In a preferred embodiment thewidth of the tip 308 of the upper seal 302 is between about 1/32nd andabout ¼th of an inch and is narrower than the width of the seal 302along other portions of the seal 302. In a more preferred embodiment thewidth of the tip 308 of the upper seal 302 is between about 1/16^(th) ofan inch and about ⅛^(th) of an inch. The downward force exerted by theconsumer will be concentrated on the tip 308, resulting in less requiredforce to destroy the seal 302 at the tip 308, thus initiating theopening of the seal 302. If the upper seal 302 did not come to a tip orwas thicker, the force would be less concentrated and consequently moreforce would be required to destroy or open the seal.

When the seal is destroyed, the force exerted gets distributed downwardand outward along the package in the same direction of the upper seal302. As the forces distribute outward, they run across a plurality(three in the embodiment illustrated) of score lines 303 a, 303 b, 303c, 303 d, 303 e, 303 f on either side of the package. As used hereinscore lines encompasses lines which have been partially scored into thematerial, completely slit through the material, or perforated. In thepictured embodiment there are three score lines 303 a, 303 b, 303 c, 303d, 303 e, 303 f which run the entire length of the package on bothsides, left and right, of the package. In one embodiment of the currentinvention, it is preferred that these score lines 303 a, 303 b, 303 c,303 d, 303 e, 303 f on either side be separated by about 1/10^(th) of aninch to about one inch. It is more preferable that the score lines beseparated by about ⅛^(th) to about ½ of an inch. It is most preferablethat the score lines be separated by about ¼ of an inch. It isdesirable, though not required, to form score lines 303 a, 303 b, 303 c,303 d, 303 e, 303 f such that when the package is filled with productthe outermost score lines 303 c, 303 f are close to the product edge.This results in a greater possible planar surface area of the plate whenthe package is opened. In one embodiment of the current invention it ispreferred that the outermost score lines be located from about 1/16^(th)of an inch to about four inches from the edge of the package.

As a consumer pulls down on the tear tab 305, the force will run downthe upper seal and into one of these three score lines 303 a, 303 b, 303c, 303 d, 303 e, 303 f. Having multiple, or in this case three scorelines 303 a, 303 b, 303 c, 303 d, 303 e, 303 f on either side ishelpful, though not required, as it provides some room for error; if thetear does not intersect the innermost slot, the tear will continue untilit intersects the outermost slot and the tear will continue to runvertical with the length of the package. As noted above, the orientedpolymer material has been specially treated so that the long polymericmolecules tend to align in a given direction, causing the material topreferentially tear in that direction. Thus, because the polymermaterial is oriented so as to align with the score lines lines 303 a,303 b, 303 c, 303 d, 303 e, 303 f, the material preferentially tears inthe same direction as the score lines 303 a, 303 b, 303 c, 303 d, 303 e,303 f. If the material was oriented perpendicular to the score line thematerial would not tear along a straight path. The polymer material istreated to cause this alignment in the formation of the material beforethe film layers are selected for lamination.

FIG. 4 depicts a top planar view of one embodiment of the instantinvention wherein the top 401 has been torn to reveal a plate of food.The top 401, once removed, can be used as a type of placemat. Forexample, cups can be placed on the top 401 instead of a coaster toprotect a tabletop. Returning to FIG. 4, it can be seen that the top 401has been torn along the middle score lines 303 e, 303 b. Two score lines303 a, 303 d are visible in the innermost layer of the torn top portion401. Additionally, two score lines 303 c, 303 f remain on the plateportion of the package. Thus, FIG. 4 shows an open package that has beenopened with a tear following the middle score line. Note that while thisembodiment has been shown with three score lines on either side of thepackage that is not so limiting. Virtually any number of score lines,from one up, is possible. Once the package is open, as depicted in FIG.4, the bag sits firmly on a surface. The torn top 401 reveals thepackage contents. In one embodiment the bag comprises snack foods suchas potato chips. A consumer would be able to consume or use thepackage's contents without the need to balance the bag for fear ofspillage. Further, the open surface of the instant invention offers agreater relative surface and allows for easier removal of the productcontents compared to prior art bags that offered only a relatively smallopening for removal of the product. Thus a consumer can easily open thepackage using the tear tab 305 and place the open package on a surface,utilizing the open package as a plate.

Referring now to FIG. 5, one aspect of the instant invention becomesclear. Whereas in FIG. 1 the outside of the bag is an OPP layer 102 andthe product side of the bag is a metallic OPP layer 106 with a sealant108, the instant invention has those layers reversed. Referring to FIG.5, in one embodiment the outermost layer of the instant invention is ametalized OPP layer 106 with a sealant layer 108. As discussed above,the sealant layer 108 can comprise barrier properties. As used hereinbarrier properties means any layer which provides a barrier to oxygen ormoisture and helps to retain taste and freshness of the productcontained therein, An OPP layer 102 is the innermost, product side layerof the package. An adhesive layer 104 is between the OPP layer 102 andthe metalized OPP layer 106, 108. Thus, whereas the metalized layer 106,108 was on the inside of the package in the prior art, in the instantinvention the metalized layer 106, 108 is actually on the outside of thepackage. The reason for this arrangement can better be seen referringback to FIG. 3. As discussed above, FIG. 3 has three pairs of scorelines 303 a, 303 b, 303 c, 303 d, 303 e, 303 f that run the entirelength of the package. It is a preferred embodiment of the instantinvention that these score lines be on the innermost layer of theinvention of the bag. As a consumer pulls on the tear tab 305, the forcedestroys the seal at the tip 308 of the upper seal 302 and continuesdownward and outward until the tear encounters a score line 303 a, 303b, 303 c, 303 d, 303 e, 303 f. Because in this embodiment the score lineis formed in the innermost layer, when the downward force is applied,the innermost layer breaks and tears in the direction of the force. Thisin turn causes the outermost layers to tear in the same direction andlocation. Thus, because the score lines 303 are located in the innermostlayer which is below the outermost layer, any force to separate theinnermost layer must cause a tear in the outermost layer.

Referring back to FIG. 5, it becomes obvious that there are manydifferent possibilities for film layers that would result in a similaroutcome of the current invention. The basic requirements of the instantinvention are that one layer comprise a score line and that one layercomprise barrier properties. These barrier properties are essential inkeeping oxygen and moisture from contacting and adversely affecting theproduct within the container. It can be appreciated that while oneembodiment has stated the use of OPP as the innermost layer, othermaterials can be suitably used. Virtually any layer that is capable oflaminating or adhering with another layer comprising barrier propertiesmay be used for the innermost layer. Likewise, while a metalized OPPlayer has been described for the outer layer, virtually any layer whichcomprises adequate barrier properties can be used.

FIG. 6 depicts the formation of making score lines 303 a, 303 b, 303 c,303 d, 303 e, 303 f in one embodiment. FIG. 6 depicts the formation ofthe packaging film of FIG. 5 wherein the innermost layer of the packageis slit completely through. It should again be noted that this inventionis not limited to situations where the innermost layer is slitcompletely through. Other methods such as scoring or perforating mayalso be used. FIG. 6 depicts a slightly altered method which wasdisclosed by commonly owned U.S. Pat. No. 7,189,300 B2 to Knoerzer etal. which is incorporated herein. First an OPP layer 102, which in thisembodiment is the innermost film in the package, is slitted. It is slitby slitters 603 resulting in a film with parallel score lines. If threescore lines on either side of the package are desired, then there willbe six total slitters. After an OPP layer 102 has been cut resulting inscore lines 303, the OPP layer 102 is laminated using an adhesive 104 tothe outermost layer comprising an OPP metalized layer 106 and a sealant108. The resulting film 500 comprises an OPP layer 102 with score lineslaminated to an OPP layer 106, 108 which comprises barrier properties.It should be noted that while reference has been made to a single filmlayer, it is possible, and may be preferred that each layer comprisemultiple layers.

FIG. 7 shows a planar view of the composite film 500 that will make upone example container or bag. The width 704 and length 706 of eachcomposite film 500 can be varied to produce bags of various sizes. Note,that if the composite film 500 is fed to a traditional form, fill, andseal machine, the composite film 500 is in a continuous sheet. It isthen formed into a tube, sealed at one end, filled, sealed at a secondend, and cut to form the resultant bag.

As an example, to produce a five inch wide bag, the width of thecomposite film 704 will be about eleven inches. If three score lines aredesired on either side of the bag, and each score line is separated byabout one-quarter of an inch, then the distance 705 between middle scorelines 303 b, 303 e will be about four inches. The distance 701 betweenthe middle score line on the right 303 e and the right side of the filmcomposite will be about 3.75 inches. The distance 703 between the middlescore line of the left 303 b and the left side of the film compositewill be about 3.25 inches. Thus, it is apparent that the distance 702between middle score lines 303 b, 303 e is dependent upon the width ofthe composite film 704, the distance between score lines 705, and thenumber of score lines. Thus, if an eight inch bag is desired, with sixscore line separated by about one-quarter inch, the resulting compositefilm would have a distance of about seven inches between the left andright middle score lines. Accordingly, if the package was opened alongthe middle score line, the resulting plate would have an open area widthof about seven inches. It should be noted that the dimensions and ratiosstated above are for one preferred embodiment and are given only as anillustrative example. Many other dimensions and ratios may also bepreferred and can be obtained without varying from the scope of thisinvention.

The composite film 500 is then fed to a traditional form, fill and sealmachine, similar to that shown in FIG. 3 but with minor alterations. Thefilm is fed such that the score lines are parallel to the direction offilm travel. An alteration made to a traditional form, fill, and sealmachine includes replacing the heat seal jaws 226 with a modified jawthat provides both the vertical bottom seal 310 and the upper seal 302as seen in FIG. 3. These modifications can best be understood byreference to FIG. 8.

FIG. 8 depicts a perspective view of the seal jaws and jaw face used inone embodiment of the current invention. FIG. 8 only shows a perspectiveview of one of the seal jaws and in operation two seal jaws would act inconcert to form both seals. The top portion of FIG. 8, the bottom sealer801, is a horizontal seal which makes the bottom seal 301. The bottomportion of FIG. 8, the upper sealer 802 seals the top portion of the bagby making upper seal 302. The upper sealer 802 as depicted has the shapeof an inverted “V” and would result in the chevron seal shown in FIG. 3.It should be noted that the upper sealer 802 can comprise variousshapes. It naturally follows that the upper sealer 802 can produce anupper seal 302 with many different shapes such as the chevron or asemi-circle. Virtually any shape which directs force downward andoutward can be utilized. It can be seen that there will be a layer offilm 805 defined by the length between the distance of the bottom sealer801 and the upper sealer 802 that is not sealed. This is what results inthe tear tab 305 that provides for easy opening. It should be noted thatthe lengths of both the bottom sealer 801 and the upper sealer 802exceed the width of the bag to be sealed. If the lengths of the seals donot exceed the width of the bag, then the entire bag will not be sealed,and oxygen and moisture will be able to penetrate the bag.

In operation, the upper sealer 802 and the bottom sealer 801 areseparated by a distance defined by the length of unsealed film 805. Thisdistance will vary from about half an inch for smaller bags to aboutfour inches or more for larger bags. The bottom sealer 801 is locatedabove the upper sealer 802 by a distance 803 defined by the separationfrom the tip of the upper sealer 808 to the bottom sealer 801. Thisdistance 803 will vary with the size of the bag. Suitable distancesinclude from about one-half an inch for smaller bags to about fourinches or more for larger bags. In operation, while the bottom sealer801 is forming a bottom seal 301 for a bag above the bottom sealer 801,upper sealer 802 is forming an upper seal 302 for a bag located belowthe bottom sealer 801. After the two seals are formed, a knife, or othermeans (not shown) cuts the film beneath the bottom sealer 801 to formtwo separate bags.

It should also be noted that the seal produced by the upper sealer 802is typically different from the bottom seal 301 in that the upper seal302 is peelable. It should be noted however, that in some embodiments itmay be desirable that the bottom seal 301 also comprise a peelable seal.As used herein a “peelable seal” is a seal which can be broken along aspecified direction of travel, and which is typically easy to open. Inone embodiment the peelable seal requires less force to destroy than adestructive seal. A destructive seal is a seal that cannot be openedwithout tearing. In many embodiments the peelable seal is easily openedwith two hands. It is possible to produce a peelable seal in many wayswhich are discussed below. In one embodiment, the geometry of the upperseal 302 is manipulated to produce a seal which is easier to open. Forexample, in one embodiment the peelable upper seal 302 comprises a lineseal. A line seal is a very narrow seal. Because the line seal isnarrow, it requires less force to destroy than a wider seal. Thus, thepeelable upper seal 302 can comprises an easy to open line seal whereasthe bottom seal 301 comprises a traditional permanent or destructiveseal. In some embodiments, the upper seal 302 and bottom seal 301comprise the same seal type, for example a permanent seal, but the upperseal 302 is narrow making it easy to open and thus peelable. In anotherembodiment the peelable upper seal 302 comprises resin in what issometimes referred to as a peelable sealant by design. Typically, insuch an embodiment resin is applied to the entire film of the package.Upon the application of heat and pressure a seal forms between the twofilms comprising layers. The strength of the resultant seal is adjustedby varying the amount of heat applied to the seal, the pressure appliedto the seal, the length of time the heat and pressure are applied to theseal, as well as the geometry of the seal. Thus, two seals of varyingstrength may be made by varying the temperature and pressure applied toa given seal. Likewise, as discussed above, one seal can be weaker andthus easier to open than a second seal if it is thinner than the secondseal. In other embodiments the resin may be applied selectively to thearea being sealed resulting in a peelable seal. In yet anotherembodiment the peelable upper seal 302 comprises a cold seal, forexample, glue. Thus, there are many methods which produce a peelableseal. Any of these methods may be used to produce upper seal 302. Inmany embodiments of the current invention the upper seal 302 requiresless force to destroy than the bottom seal 301. The reason the upperseal 302 needs to be peelable is that in the operation of this bag aconsumer grabs the tear tab and pulls downward. As the consumer pullsdownward, the force of the tab being pulled downward along the length ofthe package will be sufficient to separate the front and back layers ofthe package so that the seal is destroyed and the package is opened.Consequently, the upper seal 302 needs to be peelable to allow for thisoperation. If the seal was not peelable, then the package will just ripapart instead of following the path of the seal. Further, if the sealwas not peelable then more force is typically required to destroy it. Itshould now be noted that while FIG. 8 depicts the upper sealer 802 andthe bottom sealer 801 as being on the same seal jaw 803, it is possible,and it may be more desirable to have each sealer on its own seal jaw.Such an arrangement allows increased flexibility in forming seals withdifferent attributes.

In summary, the invention allows the production of a flexible filmhaving an easily opened package that when opened operates as a plate.Many other variations are possible without straying from the intent ofthis inventive disclosure and will be obvious to one of ordinary skillin the art.

1. A package comprising a flexible film, said package comprising: abottom seal; an upper peelable seal comprising a force distributingconfiguration, wherein said upper peelable seal has a seal area of adefined width and length; a front panel defined as between said bottomand upper seals, wherein said front panel has a right side and a leftside; a back panel contiguous with said front panel and defined asbetween said bottom and upper seal; wherein said front and back panelseach comprise at least two layers of film, an inner and an outer layer;wherein said inner layer comprises at least two score lines running fromthe upper seal and the bottom seal; and wherein said package comprisesan extension of the package film above the upper seal.
 2. The package ofclaim 1 wherein said outer layer comprises oriented film.
 3. The packageof claim 2 wherein said orientation is aligned with said score lines. 4.The package of claim 1 wherein said outer layer comprises barrierproperties.
 5. The package of claim 4 wherein said outer layer comprisesa metalized film.
 6. The package of claim 1 wherein said upper sealcomprises a tip, and wherein the seal area at said tip is narrower thanthe width of the seal area along the rest of said seal.
 7. The packageof claim 1 wherein the seal area of said upper seal has a width ofbetween about 1/16^(th) to about ⅛^(th) of an inch.
 8. The package ofclaim 1 wherein said upper seal comprises a chevron shaped seal.
 9. Thepackage of claim 1 wherein said extension of the package film above theupper seal further comprises two cuts in said front panel therebyforming a tear tab.
 10. The package of claim 1 wherein said at least twoscore lines comprise at least one score line vertically oriented on aleft side of said front panel, and wherein at least two score linesfurther comprise at least one score line vertically oriented on a rightside of said front panel.
 11. The package of claim 1 wherein said upperpeelable seal comprises resin.
 12. The package of claim 1 wherein saidupper peelable seal comprises a cold seal.
 13. The package of claim 1wherein said upper peelable seal comprises a line seal.
 14. A method formaking a flexible film package said method comprising the steps of: a)obtaining a flexible film web having a layer comprising at least twovertical score lines, wherein at least one layer within said flexiblefilm is oriented to preferentially tear in the direction of said atleast two score lines; b) feeding said flexible film into a form, fill,and seal machine such that said at least two score lines are parallel tothe direction of film travel; c) forming said flexible film web into atube; d) sealing said flexible film web at the bottom of said tube,thereby forming a bottom seal on a resultant package; e) filling saidresultant package with product; and f) sealing at the top of a resultantpackage a force distributing peelable seal wherein film material extendsbeyond said seal, and wherein said seal has a seal area of a definedwidth and length.
 15. The method of claim 14 further comprising the stepof: g) cutting said film material extending beyond said seal to form atear tab.
 16. The method of claim 14 wherein said sealing step f)comprises sealing at the top of a resultant package a chevron shapedseal.
 17. The method of claim 14 wherein said sealing step f) comprisessealing at the top of a resultant package a seal, wherein the seal areaof said seal has a width of between about 1/16^(th) to about ⅛^(th) ofan inch.
 18. The method of claim 14 wherein said sealing step f)comprises sealing at the top of a resultant package a seal, wherein saidseal comprises a tip, and wherein the seal area at said tip is narrowerthan the width of the seal area along the rest of said seal.
 19. Themethod of claim 14 wherein said obtaining step a) comprises obtaining alayer of oriented polypropylene.
 20. The method of claim 14 wherein saidfilling step e) comprises filling said resultant package with a snackfood.
 21. The method of claim 14 wherein said feeding step b) comprisesfeeding said flexible film into a vertical form, fill, and seal machine.